Battery element fabricating machines

ABSTRACT

A machine for assembling battery plates and separators into groups by the cast-on method of forming posts and straps on the plates. The machine has a central vertically movable and rotatable column with a plurality of radially outwardly extending plate holding baskets, each of which is rotatably connected to the column and movable therewith between a loading station wherein battery plates are loaded with the basket angularly oriented with respect to horizontal and wherein the plates are loaded with the lugs of the plates projecting upwardly therefrom; a fluxing station; a molding station wherein particular valve means are provided to permit rapid and accurate flow of molten lead into cavities for the formation of battery posts and straps on the lugs of the plate; and an unloading station.

United States Patent John E. Farmer Chicago, Ill.

Mar. 13, 1969 Division of Ser. No. 650,119, June 29, 1967, Pat. No.3,504,731.

Sept. 14,1971

Farmer Mold and Machine Works, Inc.

[ 72] Inventor [2 l 1 Appl. No. [22] Filed [45] Patented [73] Assignee[54] BATTERY ELEMENT FABRICATING MACHINES 8 Claims, 27 Drawing Figs.

UNITED STATES PATENTS 3,294,258 12/1966 Sabatino et al. 214/6 PrimaryExaminer Francis S. Husar Attorney-Hofgren, Wegner, Allen, Stellman &McCord ABSTRACT: A machine for assembling battery plates and separatorsinto groups by the cast-on method of forming posts and straps on theplates. The machine has a central vertically movable and rotatablecolumn with a plurality of radially outwardly extending plate holdingbaskets, each of which is rotatably connected to the column and movabletherewith between a loading station wherein battery plates are loadedwith the basket angularly orientedvwith respect to horizontal andwherein the plates are loaded with the lugs of the plates projectingupwardly therefrom; a fluxing. station; a molding station whereinparticular valve means are provided to permit rapid and accurate flow ofmolten lead into cavities for the formation of battery posts and strapson the lugs of the plate; and an unloading station.

PATENTEDSEP14 asm sum 01 0F 1 "musm 3.604.094 sum 02 0H4 mzmtusemm sum03 ur 14 PATENTH] SEP 1 4 m 3 saw on or v14 ate FIE/1 PATENTED SEP] 4I97! sum 12 HF 1 PATENTED SE? I 4 EM saw 13 [1F 14 BATTERY ELEMENTFABRICATING MACHINES This is a division of application Ser. No. 650,ll9, filed June 29, I967, and now U.S. Pat. No. 3,504,731.

BACKGROUND OF THE INVENTION 1. Field ofthe Invention This inventionrelates to machines for assembling storage battery elements and moreparticularly to a machine for assembling storage battery elements by thecast-on method of forming posts and straps on the lugs of batteryplates.

2. Description of the Prior Art Until recently, the common method ofassembling posts, straps and plates of a storage battery has been by theso-called burning" process. Simply stated, this meant that the post wascast separately and then welded to the strap produced by melting thelugs on the plates of the battery. Recently the so-called cast-on"method of battery assembly has come into use. By this method, the lugsof the battery plates are dipped into a mold cavity containing moltenlead so that the straps and posts are fused to the lugs. When the moltenlead is cooled, the adhered straps and posts are withdrawn from the moldcavity. Mechanisms for carrying out this method have been disclosed inVieth U.S. Pat. No. 2,799,905, issued July, 1957, and Sabatino et al.U.S. Pat. No. 3,253,306, issued May 31, I966.

Vieth U.S. Pat. No. 2,799,905 discloses a battery assembling machine forassembling plates by the cast-on method of welding wherein a singlehopper is mounted on a single arm which is movable from a loadingstation to a casting station and then to an unloading station. At theloading station, the plates are loaded with the lugs projectingdownwardly, and structural means are provided for aligning the plates.In addition, the Vieth patent discloses separate means at the unloadingstation for vibrating the battery plates to settle the same. Finally,the Vieth patent uses a motive means for rotating the arm on which thehopper is mounted and a separate motive means for vertically moving thecentral column to which the arm is attached between the stations in thepath of travel of the arm.

Sabatino et al. U.S. Pat. No. 3,253,306 discloses a battery assemblymachine including a central column which is rotatable between aplurality of operating stations. The column has outwardly projectingarms at the end of which there are transversely oriented batteryplate-gripping means. The gripping means are vertically movable withrespect to the arms and rotatable or swingable with the arms to movebetween the several stations as the central column moves and rotatesin-the operation of the mechanism. At the loading station of theSabatino apparatus, a separate means is provided for aligning the platesandseparator elements prior to being picked up by the gripper means atthe ends of the arms. This separatealigning or preloading means isdisclosed and claimed in Sabatino et al. U.S. Pat. No. 3,294,258, issuedDec. 27, I966. The separate loading and aligning means includes aboxlike member into which the battery plates are stacked with the lugsfacing downwardly. Structural means are provided for settling the platesin order to insure alignment thereof. The boxlike member is thenpartially rotated to be placed in a position wherein the plates can beextracted therefrom by the plategripping means on the free ends of oneof the arms of the battery assembly machine.

At the fluxing station of the. structure'shown in the Sabatino et al.U.S. Pat. No. 3,253,306 a means is provided for heating the lugs of theplates in order to prepare the plates for the molding station. At themolding station, molten lead is supplied to the cavities by dipperelements which dip into a reservoir and move towards the cavities topour-a specified amount into the cavities, withdraw, dip, and move intopouringposition and so on.

Other patents which deal. with the method of cast-on molding of strapsand posts to the lugs of battery plates are the Sabatino et al. U.S.Pat. No. 3,087,005, issued Apr. 23, I963; Sabatino et al. U.S. Pat. No.3,229,339, issued Jan. 18, 1966;

Sabatino et al. U.S. Pat. No. 3,238,579, issued Mar. 8, I966 andBronstert U.S. Pat. No. 3,072,984. Generally speaking, all of thesepatents deal with the method for improving the fusion between the caststrap and post and the lugs on the battery plates and have little to dowith disclosing structure for accomplishing the method.

SUMMARY OF THE INVENTION This invention is directed, in brief, to theprovision of a machine for assembling the plates and separators of abattery by the cast-on method wherein the machine is provided with acentral vertically movable column having radially outwardly extendingbattery plates holding hoppers or baskets which are mounted for rotationwith respect to the column. The column is also rotatable to move thebaskets between a loading station, fluxing station, molding station andunloading station. At the loading station, the baskets are rotated ontheir axes so as to be angularly oriented, and the battery plates areloaded with the lugs up, alignment of the plates being automaticallyaccomplished thereby. At the fluxing station, the battery plates aredipped into the flux and no separate means is necessary for heating theflux or heating the lugs of the plates. At the molding station, novelvalving means is provided for accurately supplying a flow of molten leadin a predetermined amount to the mold cavities.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top plan view of thebattery element fabricating machine of this invention;

FIG. 2 is a side elevational view of the battery element fabricatingmachine of this invention;

FIG. 3 is a side elevational view of the battery element fabricatingmachine of this invention taken from the side opposite that shown inFIG. 2;

FIG. 4 is a fragmentary enlarged section view taken generally along theline 4-4 of FIG. 1 with parts removed for clarity of illustration,showing generally the main drive mechanism of the battery elementfabricating machine of this invention;

FIG. 5 is a fragmentary enlarged section view taken generally along theline 5-5 of FIG. 1 and showing a portion of the means for actuating thevalve mechanism at the molding station;

FIG. 6 is a fragmentary enlarged top plan view of the molding station;

FIG. 7 is a fragmentary enlarged section view taken generally along theline 7-7 of FIG. 6 showing the valving arrangementof the molding stationin greater detail;

FIG. 8 is a fragmentary enlarged section view taken generally along theline 8-8 of FIG. 4;

FIG. 9 is a fragmentary enlarged section view taken generally along theline 9-9of FIG. l showing the disposition of the elements of the machineat the loading'station in a condition to receive battery plates to beloaded therein with the lugs facing upwardly;

FIG. 10 is a view similar to FIG. 9 but showing the elements of theloading'station prior to being placed in a condition to receive thebattery plates for stacking;

FIG. 11 is a fragmentary enlarged section view of a portion of theloading station;

FIG. l2-is-a fragmentary section view taken generally along thelinel2-l2 of FIG; 4;

FIG. 13 is a fragmentary enlarged section view taken generally along theline 13-l3 of FIG. 4;

FIG. 14 is a view similar to FIG. 4with parts removed for clarity ofillustration but showing the relationship of the elements of the maindrive mechanism when the column is in a raised position for rotatingbetween stations;

FIGS; 15 through 20 are diagrammatic view illustrating the relationshipsof specific cams associated with the main drive mechanism and thefunctional components which are operated as a result of the motion ofthe cams;

FIG. 21 is a fragmentary enlarged elevational view of the unloadingstation of the machine with the central column in the raised positionfor rotating the plate-holding carrier to the unloading station with thebattery lugs, straps and posts facing downwardly;

FIG. 22 is a view similar to FIG. 21, but with the center post havingbeen retracted so that the gears on the carrier supporting arm are inmeshing engagement with a gear for rotating the carrier 180 from theposition shown in FIG. 21, prior to the unloading of the battery groupsfrom the carrier by relative movement of the sidewalls of the carrier,to the dotted outline position to permit the gravity fall of the batterygroups held therein;

FIG. 23 is an enlarged end view of the fluxing station showing thecarrier positioned with the battery lugs oriented downwardly intoabsorbing engagement with flux saturated sponge elements;

FIG. 24 is a fragmentary section view taken generally along the lines2424 of FIG. 23;

FIG. 25 is a fragmentary section view showing in greater detail therelationship between the lugs of the battery plates and the fluxsupplying means of the fluxing station;

FIG. 26 is an elevational view ofa completed group of battery plates andspacers held together by cast-on straps having upwardly projectingposts; and

FIG. 27 is a top plan view of two such completed groups as assembled bythe battery assembling machine of this inventlon.

DESCRIPTION OF THE PREFERRED EMBODIMENT The battery element fabricatingor battery element assembly machine of this invention is intended foruse injoining a number of battery plates 12 for use in the cells of astorage battery. As best seen in FIGS. 26 and 27, plates 12 andseparators 14, are assembled into groups 16 by forming straps l8 andposts on the lugs 22 of the plates. This machine is intended for use informing such straps and posts on the lugs to produce the groups by thecast-on method. Generally battery plates 12 are gridlike structures witha lug 22 projecting outwardly along one side at the top of the plate asshown in more detail in Sabatino et al. U.S. Pat. No. 3,249,981. Forsimplicity ofillustration, the plates are shown herein as being solid,but it is to be understood that in actual practice, the plates are gridswith an electrolytic activated paste bonded to the grids.

Generally speaking, the battery element fabricating machine 10 includesa loading station 24 wherein the plates and separators are loaded; afluxing station 26 wherein flux from a fluxing pot 26a is applied to thelugs of the plates; a casting station or molding station 28 whereinmolten lead 29 is fed by pressure flow from a leadvat 29a, and cast onthe previously fluxed lugs 22; and an unloading station 30 wherein thecompleted groups 16 are dropped onto a shelf 300 or other suitablesurface from which the group 16 may be carried to be installed in abattery casing. Typically a scum 29b of lead oxide continually floats onthe top of the molten lead 29 and serves as a shield to maintain themolten lead relatively pure.

The machine 10 is provided with a frame including a plurality of uprightlegs 32 and a base 33. Housing means generally encloses the frameincluding a plurality of side panels 35 and a top cover panel 36. Themachine is provided with a central column 38 which is both verticallymovable with respect to the frame and rotatable as well. Arms 39 extendradially outwardly from a hub 39a connected to the top of column 38.Each arm 39 supports hoppers or baskets or group carriers 40 that extendradially outwardly from the arms and are adapted for holding the batteryplates and separators as the several operations are performed at thedifferent stations. The carriers 40 are rotatable relative to the arms39 and the arms are movable with the column 38. The carriers rotateabout an axis generally coextensive with each arm 39.

MAIN DRIVE SYSTEM The central column 38 is vertically and rotatablydriven by a drive system working primarily off a (icncva motion, and isbest seen in FIGS. 4 and 12 through 14.

Column 38 is mounted for rotation and for vertical movement in aslecvelike member 41. A motor 42 is connected to the base 33 of theframe and drives a pulley 43 about which is reeved a drive belt 44.Drive belt 44 is also reeved about a large drive pulley 45 which isconnected to a rotatable shaft 46. On the opposite end of shaft 46 is asmall pulley 47 which drives a belt 48 also reeved about an intermediatesize pulley 49. Pulley 49 is connected to a shaft 50 which extends intogear housing 51. Suitable gearing (not shown) in housing 51 transmitsthe motive force from the rotation of shaft 50 to rotate the uprightlyextending cam drive shaft 52 through 360 to rotate central column 38through Vertical drive cam 53 and rotatable drive cam 54 are fixed oncam drive shaft 52. Vertical drive cam 53 has an upstanding eccentricsurface 55 which is intended for engagement with a rollerlike follower56 on the lower end of shaft 38. As shaft 52 rotates and surface 55comes into engagement with follower 56, the shaft 38 will intermittentlymove between a position of vertical retraction as shown in FIG. 4 andfull vertical extension as shown in FIG. 14.

The rotatable drive cam 54 includes a generally arcuate or circularouter surface 57 which is interrupted by an inwardly extending radialrecess 58 defined by surfaces 580 and 58b. A depending stud 580 ismounted in the area of recess 58. A follower 59 is fixed to the shaft 38for rotating the shaft while permitting relative vertical movementthereof. Follower 59 includes four outwardly facing circular segmentalarcuate surfaces 60 which are separated by four protruding portions 60a,each having an inwardly facing slot 61. The surfaces 60 on follower 59and surfaces 57 on cam 54 are in a face-to-face sliding relationshipwith each other. After side 58a of the recess 58 passes a slot 61, stud580 will engage therewith and rotate the follower for a portion of arevolution of the cam 54, while protrusion 60a extends into recess 58.This will rotate the follower 59 and column 38 to effectuate timedintermittent movement of the arms between the several stations relativeto the vertical movement imparted by cam 53, the rotatable movementoccuring when column 38 is in the raised position shown in FIG. 14.

GROUP CARRIERS As best seen in FIGS. 8 through 10 and 21 through 24,each of the carriers on baskets 40 includes an outwardly opening U-shaped member or box 62 comprised of parallel sidewalls 63 spanned by arear wall 64. A plurality of partitions 65 with padded portions 65aextend transversely between the sidewalls 63 to generally define plateand separator confining areas or compartments normally of the order tohold a number of such plates and separators as will constitute a group.Preferably the distance between sidewalls 63 is slightly larger than thewidth of separators and plates to be carried, affording some latitudefor ease ofloading and unloading.

A shaft 66 extends rearwardly from the rear wall 64, generally inalignment with the arm 39, the shaft 66 providing a means for rotatingthe baskets about an axis relative to the arms 39. The shaft extendsthrough a collar portion 67 in arm 39 and into a recess 68 in the hub39a wherein it is rotatably mounted by suitable means, such as bearings70. A miter gear 71 is fixed to the shaft 66 and a torsion return spring72 is connected to shaft 66 and the arm 39 to return the baskets 40 to agenerally horizontal orientation after being rotated by driving means inengagement with gear 71 as will be explained later.

Further included in the carrier assembly is a telescopically relatedsleevelikemember 73, comprising a pair of side panels 74 joined togetherby a bridge member 75 of generally U- shaped configuration including aspanning portion 750 which arches over shaft 66. A spring 76 is fixed topanels 74 at 76a and to sidewalls 63 at 76b to normally urge the sleeve73 and box 62 togetherin a retracted. plate-gripping position.

The side panels 74 include upper and lower inwardly extending flanges 77and 78 which embrace the sidewalls 63. Plate-gripping ribs 79 extendgenerally uprightly between the flange portions 77 and 78 and aremovable toward and away from the partitions 65 in the box 62 as thesleeve member 73 is moved relative to the box. allowing the ribs toalternately grip plates and separators between the ribs 79 and thepartitions 75 to thereby hold groups in the carrier, or to release thegripping engagement to permit the loading or unloading of groups fromthe basket. Ribs 79 also have pads 79a which, like pads 65a, are of asuitable resilient substance, such as sponge rubber or the like, toprevent damage to the plates when ribs 79 and partitions 65 are in aplate-gripping relationship. A set of pads 65a and 79a are also spacedinwardly from one sidewall of the group carrier to provide surfaces foraccommodating narrower groups of plates and separators.

In the plan view FIG. 1, the carriers 40 are shown as empty so that therelationship of the elements may be more easily understood. The ribs 79are retracted from partitions 65 at the loading station to permitloading while the ribs are in plategripping relation to the partitionsat the fluxing and molding stations.

MEANS FOR ROTATING GROUP CARRIERS The means for rotating the carriers isshown in FIGS. 4, 5, 8, 12, 14 and 21 through 22. Referring first toFIG. 12, the means includes a cylinder 81 mounted under a bracket 81a(FIGS. 1 and 2). Preferably the cylinder is of the double acting typehaving the usual linearly extensible rod 82. The end of the rod ispivoted at 83 to a crank arm 84 which is connected at 85 to a shaft 86.Shaft 86 is rotatably mounted in a sleeve means 86a connected to thehousing of the machine so that as the rod 82 is moved linearly withrespect to the cylinder 81, the shaft 86 will be rotated thereby.

Turning now to the remaining aforementioned figures, a gear 87 ismounted on the shaft on the exterior of the housing top 36, the free endof the shaft 86 being rotatably journaled in an arm 87a which is fixedto the top 36. Gear 87 is in meshing engagement with a loading stationgear 88 which is fixed to a shaft 89 rotatably mounted in a sleeve 89aon the top 36 of the housing. The free end of shaft 89 has a pinion 90which is arranged for meshing engagement with gears 71 on each shaft 66of each basket 40 when the carriers are lowered at the loading station.

Gear 87 is also in meshing engagement with the unloading station gear 91which is fixed to sleeve 92a rotatably mounted about a stub 92 connectedto the housing top 36. Sleeve 92a has a pinion 93' at the free endthereof which is also arranged for meshing engagement with the gear 71on shaft 66 of each carrier 40 when the carriers are lowered at theunloading station. Loading station gear 88 is larger than unloadingstation gear 91 so that each revolution of gear 87 responsive toextension and retraction of rod 82 will cause greater revolution of theunloading station pinion 93 than will be effectuated at the loadingstation pinion 90. Therefore, carriers 40 at the loading station 24 willbe rotated through a lesser degree of movement than those at unloadingstation 30. In the illustrated embodiment, the carriers 40 are rotatedthrough 180 at the unloading station and l35 at the loading station.

MEANS FOR MOVING CARRIERS BETWEEN AN OPEN LOADING OR DUMPING POSITIONAND A CLOSED PLATE HOLDING POSITION As best shown in FIGS. 8, 21 and22', means are further provided for moving the carriers between an openposition wherein plates and separators may be loaded or completed groupsmay be unloaded, and a closed position wherein loaded plates andseparators may be held as groups during travel between the fluxing,molding, and unloading stations. The means for performing the functionof causing relative movement between the sleeve 73 and box or U-shapedmember 62 of the carrier 40 is generally designated 94 at the loadingstations and 94a at the unloading stations.

Included in means 94 and 94a is a single-acting cylinder 95 and 95a,respectively, each of which is fixed to the housing top 36. Eachcylinder 95 and 95a has a linearly extensible rod 96 and 96a which ispivoted at 97' and 97a to an arm 98 and 98a. respectively. Each arm 98:and 98a is also pivoted" at 99 and 990, respectively, to the housing 36.A follower member 100 and 100a, preferably in the form of a roller, ismounted on each arm 98 and 98a, respectively. Return springs 10] and101a are connected at 102 and 10211 to each arm 98 and 980,respectively, as well as being connected to means associated with thehousing at l03'and 103a, respectively.

When the carriers 40 are in an upright or slightly angularly orientedposition as shown in FIGS. 8 and 22, each bridgespanning portion 750. isadjacent follower 100 and 100a so that the carriers 40 are in a positionto be acted upon by the means 94 and 94a. In particular, as each rod 96and 96a extends outwardly from cylinder 95 and 95a, respectively, eachfollower 100 and 100a pushes the bridge-spanning portion 750 of eachcarrier in opposition to the springs 76. This causes relative movementbetween the box 62 and sleeve 73 such as to cause the ribs 79 of sleeve73 to move away from the partitions 65. This relative movement and thelatitude affording the distance between sidewalls 63 provides ample roomfor plates and separators to be inserted in the carrier 40, or to permitfree withdrawal of completed groups from the carrier. When the actuatingforce is released from each of cylinders 95 and 95a, the return springs101 and 101a retract each rod 98 and 98a, respectively. At the sametime, the return springs 76 on the carrier 40 cause relative movement.between the boxes 62 and the sleeves 73 such as to move the ribs 79toward the partitions 65 in a plate-gripping position wherein the pads65a and 79a will firmly squeeze the plates and separators together andhold the same against movement relative to the carrier 40.

MEANS FOR LOADING AND ALIGNMENT OF PLATES As best shown in FIGS. 9 and11 and seen also partially in FIGS. 4 and 14, means are provided at theloading station 24 for permitting initial loading and simultaneousalignment of the several plates and separators into the carriers 40.Included in this means is a cylinder 105 which is pivoted by pin 106 tobracket 107 at its lower end. The cylinder includes the usual linearlyextensible rod 108 provided with a yoke 109 at its free end. Mechanicalreturn means, such as a return spring (not shown), is provided in theinterior of cylinder 105. A pin 109a extends through yoke 109 and an eye10912 on the underside of swingable base member 110. While base 110 isshown as spanning the walls of the group carrier, it is to be understoodthat the base need only occupy a portion of the space between the wallsto support the plates and separators during loading. A pin 111 isconnected to a plate 111a which is movably mounted on the housing 36.Pin 111 provides a pivotal mounting for the base 110 to permit it to beswung from a position of retraction, as shown in FIG. 10, to a positionwherein the plate loading and alignment function can be performed, asshown in FIG. 9

It is desirable to maintain the distance that the lugs extend above thegroup carriers a constant for proper orientation of the lugs at thefluxing and casting stations. To this end the location of base 110, whenit is in the plate-loading position, may be changed by moving plate 111ato move pin 111. Plate 111a is slotted at Illb and nuts 11 10 extendthrough the slots into housing 36. This connection provides a means formoving plate 111a, and also pin 111, laterally, to change the pivotalaxis of base 110. Changing the pivotal axis of base 110 provides a meansfor adjusting the loading station to receive elements and separators ofdifferent height.

Base 110 is provided with a separate eye 112 on its underside to whichcurved arm 113 is connected. Arm 113 tracks through a guide 113afastened on the side of housing 36. The opposite end of the arm 113 isprovided with a stop means in the form of a nut 114 which provides apositive limit to the swinging movement of the base 110 responsive toactuation of 1 cylinder 105 and the linear extension of rod 108.

At the start of a cycle, the carrier 40 which is located at the loadingstation 24 is angularly oriented about a 45 angle as shown in FIG. 9.The cylinder 105 is actuated to swing the base member 110 in a positionwhere it spans the bottom of the carrier 40. The several plates 12 andseparators are loaded in the carrier, the means 94 having been actuatedto spread the ribs 79 away from the partitions 65 to allow sufficientspace for easy positioning of the plates 12 and separators 17 in thecarrier 40.

Preferably the plates are loaded with the lugs 22 facing upwardly,although this invention could be utilized in loading plates with thelugs facing downwardly.- The angular orientation of the carriers at theloading station permits automatic aligning of the plates and separatorsby virtue of the fact that two surfaces of the plates 90 apart will besimultaneously abutting mating surfaces formed by the interior of thewall 63 of box 62 and the interior of the base 110. Distinct advantagesresult from loading the plates with the lugs up. The operator canvisually inspect to determine that all of the plates have satisfactorylug structures and further that the lugs are properly oriented in theirnormal array through the assembly. The separators are initially flushwith the bottom of the plates and do not have to be subsequentlyvibrated or otherwise displaced in the group.

It is intended that the plates and separators would be first loadedstarting from the end wall 64 and working outwardly. A switch element115 of switch 116 extends upwardly from the base member 110 and ispositioned in the general area wherein the last group of plates andseparators are to be inserted into the carrier. This switch is connectedto the means for initiating the cyclic operation of the assembly machinethereby coordinating the automatic cycling of the machine with the speedof the individual operator or mechanism loading the plates andseparators. Thus when the last group of plates and separators is loadedin the basket as shown in the position in FIG. 9, the switch element 115will be moved, causing the switch 116 to send a signal which willactivate the drive means to drive the machine and move the column 38 andarms 39 through 90. When this occurs, the cylinder 95 will be released,causing relative movement between sleeve 73 and box 62, so that the ribs79 come into plate gripping relation with the partitions 65 to firmlyhold the previously aligned plates and separators in the carrier 40. Thecylinder 105 is then deactivated to return the rod 108, causing the basemember 110 to be returned to the position shown in FIG. 10. Next,cylinder 81 is actuated to rotate carrier 40 at the loading station sothat the carrier will be oriented with the lugs facing downwardly.Following this, the column 38 is moved vertically upwardly, rotated 90,and then retracted to move the carrier from the loading station to thefluxing station with the lugs 22 of the plates 12 facing downwardly in afluxing position.

Referring to FIG. 13, as column 38 approaches the end of 90 of rotation,finger 117 on cam 53 will strike switch arm 117a of switch 11712. Thiswill cause switch 117b to send an appropriate signal for deactivatingmotor 42, such as by opening a relay (not shown).

FLUXING STATION As best seen in FIGS. 23 through 25, and also partiallyseen in FIGS. 1 and 3, the fluxing station 26 includes a generallyradially outwardly extending tray 118. The tray 118 includes upwardlyextending sidewalls 118a and 118b and an upwardly extending end member118a. Flux applying means in the form of a pair of elongate sponges 119are placed adjacent each sidewall 118a and 118b to absorb fluxingsolution 120. The fluxing solution is supplied from a line 121 whichextends from the fluxing pot 26a and is dispensed into tray 118 throughnozzle 122. As best seen in FIG. 25, when the baskets 40 are at thefluxing station, the lugs 22 are pressed into the sponges 119 so thatthe fluxing solution is applied to the free ends of the lugs. Thisprepares the lugs for immersion in the molten lead at the castingstation 28 upon successive movement of the carriers 40 to the nextstation. For fluxing narrower plates, ad-

ditional sponges 119 could be placed adjacent each sponge 119 shown, orwider sponges (not shown) could be used.

The sponges are slightly higher than the intended level of the fluxsolution, providing a means for adequately fluxing lugs of differentheights without dipping the lugs directly in the solution. In addition,the possibility of the separators being dipped into the flux solution issubstantially eliminated.

CASTING OR MOLDING STATION Referring initially to FIGS. 4 and 14,casting station 28 is provided with means 123 for registering the groupcarriers so that the lugs will be properly oriented with respect to moldcavities. Means 123 includes an upstanding member 123a on housing top 36having a first registration element in the form of a pin or free end123b. A hollow sleeve 1230 is provided in the collar 67 of arm 39 andforms a second registration element for receiving pin 123 to registergroup carriers 40 as they are lowered at the casting station.

As best seen in FIGS. 5 through 7, and as seen also to some extent inFIGS. 1 through 3, casting station 28 further includes a mold block 124which is mounted on outwardly extending arms 125. Dams 126 are mountedat the top of the mold block 124, adjacent each sidewall thereof. Dams126 have recesses or cavities 127 for receiving the molten lead whichwill be cast as the strap portions 18 on the battery groups. Thecavities 127 may be provided with a negative sign 127a or a positivesign 127b so that the finished cast strap will have the appropriateindicia thereon indicating to the battery assembler the proper manner inwhich the group should be assembled.

Post recesses 128 and 129 are provided in the mold block adjacent to,and in communication with, the strap cavities 127 so that the postportions 20 will be integrally cast with the straps 18. Post pushers 130and 131 define the bottom of the cavities 128 and 129. These pushers areconnected to a plate 132 with plate retraction means in the form ofsprings 133 between the bottom of the mold block 124 and the plate 132.

Turning momentarily to FIGS. 2 and 4, the plate 132 is supported on arod 134 which is pivoted at 135 to an arm 136 which extends into theinterior of the housing. Arm 136 is pivoted to the frame at 136a and isprovided with a follower 137 on its free end in a position to be engagedby the depending cam surface 138 on cam 53.

As the cam shaft 52 rotates, the cam surface 138 will come in contactwith follower 137 causing arm 136 to urge the rod 134, and therefore thepost pushers 130 and 131, upwardly, which will have the effect ofbreaking the cast straps and posts outwardly from the mold in timedrelationship to the lifting of the carrier 40 from the casting stationpreparatory to moving to the unloading station.

Returning to FIGS. 5 through 7, the mold block is provided with moldheaters 139 for initially heating the block to a sufficient temperature(preferably 375 F.) to maintain the lead molten as it is initiallyintroduced to the casting station to control the rate of solidificationof the lead until after the lugs have been dipped into the molten leadand the lug lead has melted to establish a bond upon cooling of themolten lead. After a period of time, heat transfer from the molten leadwill maintain the casting station sufficiently warm and the heaters maydeactivate. A mold temperature sensor 140 is also provided for sensingthe temperature of the mold and cavities so that the heat thereof can beappropriately regulated. Water lines 141 and 142 circulate water throughwater conduits 141a and 142a in the central portion of the mold block134 which are connected at one end by a U-shaped connection 142c. Waterfed through conduits 141a and 142a cools the block and balances heattransfer of the molten lead to maintain the block at a desiredtemperature.

The lead is supplied from the vat 28 by conduits 144a and 14417 whichextend into manifolds 145 at opposite sides of the mold block 124. Eachconduit 144a and 144b has a heater element l44c and 144d, respectively,which is connected to electrical lead 144e. Each manifold has alongitudinally extending bore 146 through which the lead flows, and atemperature sensing means 146a is maintained in at least one of themanifold bores for sensing the temperature of the lead. Heaters 1461)and 146a are provided in the manifold preferably diametrically oppositebore 146 to maintain the molten lead at a high temperature such as 900F. Ducts 147 lead from the bore 146 of each manifold 145 and are incommunication with the valve blocks 148. Each valve block 148 ispositioned adjacent a cavity 127 in each dam 126. In particular, theducts 147 of the manifolds communicate with lead supplying valvepassages 149 in each valve block 148. Valve passages 149 extend in ageneral upward inclination to the area adjacent the mold cavities.

A valve seat 150, preferably of a truncated frustoconical shape, isprovided in each valve block 148 intersecting the valve passage 149. Atruncated frustoconical cock 151 is seated in each seat 150. Cock 151has a through passage 152 so that the valve passageway may beselectively opened and .closed by aligning the passage 152 of cock 151with the passage 149 of block 148, or by rotating the same out ofalignment therewith. When clock 151 is closed, molten lead remains inpassage 149 on both sides of cock 151 to shield the cock. Preferablypassage 152 is slightly smaller than valve passage 149. Also, preferablypassage 149 terminates in an outwardly diverging spoutlike end opening149a (FIG. 6).

By the described arrangement, molten lead 29 is fed from vat 290 throughconduits 144a and 14412, manifolds 145 and valve blocks148 to the moldcavities without exposure to air. Thus, the possibilities of abrasiveoxides forming in the lead somewhere in the path of flow issubstantially eliminated.

Opposite ends 1530 and 153b of the cock extend outwardly from the valveblock 148. End 153a is connected to a link 155 pivoted at 156 to agenerally upright arm 157. End l53b is :gripped by a spring washer 153;,preferably of inconel metal,

'to hold the cock 151 in seat 150. A nut 157a threaded on the farm abutsa spring 157b. A wing nut 158 threaded on the lower end of the arm holdsa connector 159 which is pivoted to connecting arm 160 at 1600.Connector 159 also holds the spring 157b on the arm 157. Connecting arm160 is secured to rod 161 at its opposite end, the rod 161 beingrotatable in a sleeve 162 mounted on a bracket 163 which depends fromeach of the arms 125.

A master crank arm 164 is fixed to each of the rods 161.

Arm 164 is provided with a slotted end and a nut and bolt connection 166connects one of the scissorslike crank arms 167 to "each of the arms164. Arms 167 are connected at their op- ;posite ends 167a to a clevis168 which is fixed to the linearly extensible rod 169 of cylinder 170.Cylinder 170 is ounted on a bracket 171 which extends outwardly from theframe. Preferably cylinder 170 is of the single-acting type and istherefore provided with return springs 172 connected to the clevis at172a and to the bracket l72b for returning or retracting the rod 169after extension thereof.

Lead is supplied to the casting station in timed relation with the othercyclic operations of the machine by activation of the rod 169 whichmoves the arms 167 upwardly and outwardly to .cause arms 164 to rotaterods 161. As rods 161 rotate, arms 160 will lift arms 157, causing thelinks 155 to rotate each cock 151 so that the passage 152 is inalignment with the valve passage 149 ofeach of the valve blocksl48. Leadflows from the manifold through passage 147 and passage 149 of the valveblock into the cavities 127, 128 and 129 of the molding station.

After a predetermined length of time, the fluid supply to cylinder 170is exhausted, and the return springs cause the rod 169 to retract,shutting off the flow of lead to the casting station. Simultaneous withthe cessation of the flow of lead, the lugs 22 of the plates are dippedinto the molten lead as the r'plate-holding baskets are brought to thecasting station and =descend thereat. After the plates are loaded at theloading station and the switch 116 activated, the cam surface 138 of cam58'strikes the follower 137 of arm 136 which, in turn, causes the rod134 to act upon the pushers 130 and 131 to push the post portions 128and 129 upwardly at the same time that the plate-holding basket 40begins its upward movement to withdraw the cast post and straps from thecasting station.

The post and slot connection between arms 164 and 167 provides a meansfor changing the degree of rotation of rod 161 responsive to actuationof the cylinder so that the amount of lead supplied by all of the valves148 may be adjusted accordingly. In addition, dispensation of lead fromeach of the valves 148 is individually adjustable by means of the nutand spring arrangements 157a and 157b and 158.

Spacer 173 is interposed between conduits 144a and 144b. When it isdesired to cast narrow groups of plates and separators, spacer 173 isremoved and a narrower mold block 124 is mounted on arms 125. Alignmentmay be accomplished at all times along the side of the mold to whichconduit 144a extends.

The passage 149 is preferably slightly larger than opening 152 throughthe cock '151 to minimize the effect of any build up of lead oxides inthe passageway. As a result, lead is actually metered by the size of theopening 152 in the cock 151. Fluid passage 149 is slightly upwardlyinclined so that lead will not drain out the valve passage after thecock 151 is moved to the closed position. This affords a more precisemetering of the lead by the valve. Preferably the volume of passages 147and 149 is related to the volume of the cavities 128 and 129 so that theamount of lead in passage 147 and 149 will not quite fill cavities 128and 129. Lead which remains in passages 147 and 149 is slightly coolerthan the lead which is in the bore 146 of the manifold. By thevolumetric relationship mentioned, the coolest lead will go to the postcavity and the hottest lead from the manifold lines will go into thestrap cavity. This is most desirable in that the breakdown of lead oxideand melting of the lead of the lugs 22 is more efficiently accomplishedby the hotter lead.

in the preferred embodiment, the manifold bore 146 is aboutthree-fourths inch in diameter, the manifold duct147 is about seventhirty-seconds inch in diameter, the cock through passage 152 is aboutthree-sixteenths inch in diameter, and valve passage 149 is about seventhirty-seconds inch in diameter. The spoutlike opening 149a is formed inabout the last one-half inch of passage 149 and is about seventhirty-seconds inch high and three-eighths inch wide.

The oblate configuration of the spout end 149a acts to spread the flowof lead from the valve block. This prevents the possibility of leadsquirting outwardly and overshooting its intended destination in thecavities 127 and 128 or 129. in addition this enlarged area reduces thepressure of the lead flow so that the lead runs partly over the dam topreheat the sides of the cavity 127 prior to the continuation of thelead into the post cavities.

Cock 151 is made of a suitable hard metal, such as steel, which is thenheat treated and subsequently surface treated by exposure to nitridegas. One of the problems in supplying molten lead through a valvingarrangement has been that of the galling and sticking of valvecomponents as a result of the amounts of the extreme high temperaturesto which the components are subjected. Frequently the molten lead is ata temperature of 900 F. to 950 F. in the valve block. Previous effortsto design suitable valves have been unsuccessful due to these hightemperatures and the presence of lead oxide which may build up on thevalve elements during use. It has been found that by forming the cock asmentioned, and then heat treating and surface treating the same withnitride gas, the problems of galling and sticking are eliminated withthe result that the valve arrangement disclosed herein operatescontinuously to supply accurate amounts of lead to the cavities.

UNLOADING STATION The unloading station 30 includes thepreviouslydescribed means for rotating the group carriers. When the carriersarrive at the unloading station, they are in the inverted position asshown in FIG. 21, with lugs and straps pointing downwardly.

1. In a machine for fabricating storage battery elements composed ofseparators interposed between plates having lugs, a loading station,comprising: means defining a battery element carrier said carrier beingconnected to the machine for movement toward and away from the loadingstation for reception of battery elements at the loading station anddelivery of the battery elements to other portions of the batteryfabricating machine, said battery element carrier, including spacedsidewalls; means defining a carrier bottom, at least one of saidsidewalls and bottom being generally shaped to closely embracecorresponding portions of side and bottom edges of battery elements tobe loaded therein; means for orienting said carrier so as to receivebattery elements including means positioning one of the carriersidewalls and the bottom gEnerally out of vertical and horizontalorientation, respectively, whereby elements loaded into the carrier willbe gravity urged into edgewise engagement with the bottom and said onesidewall to thereby align the elements by means of edge contact betweenthe elements and the bottom wall and one sidewall.
 2. The batteryfabricating machine of claim 1 wherein the carrier has portions defininga battery elements holding compartment and gripping means for holdingthe elements in the compartment, said gripping means being movablebetween an open position wherein elements may be loaded or unloaded fromthe carrier and a gripping position wherein the elements are held in thecarrier by the mutual cooperation of the gripping means and the portionsdefining the said compartments.
 3. The battery fabricating machine ofclaim 1 wherein the bottom of the carrier is movable from a supportingposition during a loading operation to a nonsupporting position after aloading operation is completed, the bottom when in supporting positionbeing located adjacent the lower edge portions of the carrier sidewalls.4. The battery fabricating machine of claim 1 wherein the carrier ismounted on the machine for rotation about its own axis and means areprovided at the loading station for rotating the carrier to position thesame with at least one of the sidewalls out of vertical orientation. 5.The battery fabricating machine of claim 4 wherein the carrier bottom ismovable from a supporting position during a loading operation to anonsupporting position after a loading operation is completed, thebottom when in supporting position being located adjacent the lower edgeportions of the carrier sidewalls.
 6. The battery fabricating machine ofclaim 1 wherein the carrier has portions defining a battery elementholding compartment and gripping means for holding the elements in thecompartment, said gripping means being movable between an open positionwherein elements may be loaded or unloaded from the carrier and agripping position wherein the elements are held in the carrier by themutual cooperation of the gripping means and the portions defining thesaid compartments, the bottom of the carrier being movable from asupporting position during a loading operation to a nonsupportingposition after a loading operation is completed, the bottom when insupporting position being located adjacent the lower edge portions ofthe carrier sidewalls, and means are provided at the loading station formoving the gripping means between the open and closed position, saidmeans being actuable to move the gripping means to the closed positionto hold the elements in the carrier prior to the removal of the bottom.7. The battery fabricating machine of claim 1 wherein the carrierincludes a first member having spaced sidewalls and an open top andbottom with partitions extending between the spaced sidewalls, and asecond member telescoped relative to the first member and having an opentop and bottom and gripping means movable toward and away from thepartitions between an open loading or unloading position and a closedholding position, the carrier being mounted in the machine for rotationabout its own axis with means at the loading station for rotating thecarrier to position the sidewalls thereof out of vertical orientationand for moving the second member so as to position the gripping means inthe open position upon movement of the carrier to the said nonverticalorientation, the carrier bottom being movable between a retractedposition away from the carrier and a loading supporting positionspanning the sidewalls of the carrier when the carrier is positionedwith the sidewalls out of vertical orientation.
 8. The batteryfabricating machine of claim 7 including means at the loading stationresponsive to loading of the carrier for first moving the grippingmembers to a closed element-holding position, secondly moving the basemember to the retracted position and subsequently rotating the carrierTo orient the same with the plate lugs facing generally downwardly andbeing held in alignment by the cooperation between the gripping meansand the partition.